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800 kV Ultra HVDC Transformer – A new dimension of DC Transmission

Conference Paper · January 2009

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 Second International Symposium on Standards
for
Ultra High Voltage Transmission

800 kV Ultra HVDC Transformer – A new dimension of DC Transmission

MARIO SCHENK PETER HEINZIG UWE RIMMELE JENS HOPPE

Siemens AG Siemens AG Siemens AG Siemens AG
E T TR PN EN E T TR PN T E T TR PN EN2 E T TR PN EN1
Germany Germany Germany Germany

Energy Sector, Transmission Division, Transformers, Power Transformers Nuremberg

SUMMARY

A new voltage level is introduced with a transmission voltage of 800 kV for high-voltage DC
transmission.
The development, design and production of HVDC transformers differ from those of
conventional transformers in terms of certain details, and therefore pose a special challenge
for manufacturers. In particular, the insulation not only has to be dimensioned for AC stress,
but also for DC stress and polarity reversal. This applies especially if this has to be done for a
new voltage level that has not yet been put into operation.
A multitude of detailed solutions, that had previously not been used on transformers in such
systems, were necessary for the 800 kV HVDC transformers. The higher voltages call for
appropriately modified insulations which, in turn, place high demands on material and
production processes. In combination with the required transport dimensions, the greater
insulation distances call for distribution of the power to three limbs of a single-phase
transformer instead of two.
The three valve windings are connected to one another via an external valve leads that can be
dismantled. For testing, not only the availability of generators for producing the test voltage,
but also a setup free of partial discharges, poses a major demand.
Some of these special characteristics are explained in the report with reference to examples.

KEYWORDS

800kV HVDC Transformer, UHVDC, High Voltage DC Transmission, Bulk Power Transmission

schenk.mario@siemens.com
1 INTRODUCTION

In various global regions there is need to transport maximum quantities of energy, efficiently
and cost-effectively over long distances, to meet the constantly growing demand for energy.
To master this technical challenge, the 800 kV voltage level was chosen for HVDC, which
cuts the transmission costs by about 25% in comparison with those of the 500 kV DC systems
mainly used so far.
To set up the transmitting and receiving stations of such transmission links, HVDC
transformers are needed that feed the corresponding rectifier bridges. The development of
such transformers for the new 800kV UHV DC voltage range represents a particular
challenge.
For conventional transformers, the last time such a development step took place was around
40 years ago, with the widespread setting up and expansion of the 765 kV AC voltage level.
Higher voltage levels have only been created in a very small number of countries, and have
not achieved any commercial importance up to now. In high-voltage DC transmission
(HVDC), 600 kV has for decades been the highest transmission voltage, actually put into
effect in only one system. After that, all HVDC links were set up with a maximum
transmission voltage of 500 kV DC, used for the first time in the 1970s.
In the development of 800 kV transformer technology, new solutions were devised in several
fields (for example in design and production) that, to some extent, differ substantially from
previous known solutions. Some of these special characteristics are explained below with
reference to examples.

2 800 KV HVDC TRANSFORMERS

2.1 System and general transformer design

Due to the high transmission power, mostly single-phase transformers are used for long-
distance HVDC systems, in order to comply with the dimensions and masses stipulated for
transport. On the valve winding side, these are connected in star or delta configuration to feed
six-pulse rectifier groups which, when connected in series, result in a 12-pulse rectifier group.
While two six-pulse bridges result in the full transmission voltage for one pole in the
numerous 500kV systems, four series-connected bridges are used for 800 kV HVDC systems,
each of which generates 200kV DC (Fig. 1).
500kV HVDC 800kV HVDC
+200 kV
800 kV transformer
+200 kV
+800 kV
+250 kV +200 kV
+500 kV
+250 kV
+200 kV

-250 kV -200 kV
-500 kV
-250 kV -200 kV

Fig. 1: Schematics of 500 kV and 800 kV HVDC systems

1
Due to the arrangement of the transformers in the rectifier circuit of the bridges there is a need
for differing insulation levels, which in this case lead to transformers for the 800 kV, 600 kV,
400 kV and 200 kV DC voltage levels. (Fig. 2)
Only the transformers of the upper 800 kV bridge are considered below.
As already mentioned, the resulting dimension and weight restrictions had to be met in order
to ensure railway transport of the units for the first installation in China. At the same time, the
proven design criteria regarding dielectric stresses of 500 kV HVDC systems had to be
applied on the insulation systems of 800 kV HVDC transformers.
The transformer concept developed with these boundary conditions in mind therefore has the
following special characteristics:

• Single-phase transformer with five-limb core, i.e. three wound limbs and two
unwound return limbs.
• Connection of the valve windings by an external link that can be dismantled for
transport.
• Cooling system on the transformer cover.

Technical data
Rated power: 250 MVA
Vector group: Ii0
Ratio: 525 kV/√3+22.5-7.5 %/168.85 kV/√3
Total weight: 512 t, oil: 142 t
Dimensions: 26.1m x 15.2m x 6.4m
Insulation level
Line winding:
LI 1550 kV SI 1175 kV AC 680 kV
Neutral:
LI 185 kV AC 95 kV
Valve winding:
LI 1800 kV SI 1600 kV
AC (1h): 909 kV
DC (2h): + 1254 kV
PR (90min/90min/45min): ± 969 kV

Fig. 2: Technical data and schematic illustration of the 800 kV HVDC transformer

2.2 Core
As already mentioned, it was necessary to split the power within the transformer over three
limbs. Therefore, the windings of each limb are electrically connected in parallel. This is an
unusual solution for a single-phase transformer in this order of magnitude.
The three limbs' cross-sections are identical, and the cross-sections of the yokes and of the
two return limbs each amount to 50% of the limb cross-section, as is known in single-phase
transformers with return limbs. Thus, the core is geometrically similar to the normal five-limb
three-phase core. However, the flux distributions with regard to location and time are
completely different.
Accordingly, extensive magnetic simulations were run in advance to determine the no-load
losses, no-load currents and noise development. The correctness of the simulation models was
reviewed on "normal" five-limb three-phase transformers with similar dimensions. Thus,
induction loops were installed to determine flux distribution.

2
As is known in HVDC systems, attention must be paid in design of the core to the fact that
asymmetrical magnetic modulation may take place (due to operation on the rectifier system)
as a result of the DC components in the individual windings. This leads to increased no-load
currents and losses, which must be taken into account in the thermal design. During operation,
these DC components also produce increased noise and vibrations.
Domain-refined magnetic steel sheets with a thickness of 0.27 mm are used for the core
plates. All limbs are bandaged with fiberglass-reinforced epoxy. With a total length of over
10.5 m, it is the longest core produced at the Nuremberg transformer factory to date.

2.3 Windings and winding insulation

The windings in an HVDC transformer are not basically different from those in a
conventional transformer. Conventional winding types were also used for the 800 kV
transformers.
Corresponding to the insulation level, the windings were arranged in the order of tapped
winding, high voltage line winding, and valve winding, starting from the core. The order is
also due to the outer high voltage connection of the valve windings.
The tapped winding is an interleaved multi-start layer winding. A coil winding with axially
interleaved entrance area is used as the primary voltage winding. The valve winding is also a
coil winding, where capacitive control of voltage distribution is achieved via so-called field
control or shielding conductors which is located inside a twin CTC [1]. The types of windings
chosen allow the use of CTC conductors in all windings. In these conductors lower losses are
produced in comparison with flat conductor windings, especially at the windings' ends. In the
thermal design, the current harmonics arising during rectifier operation must be taken into
account. These cause loss increases of 20% to 40% in comparison with pure operation with a
sinusoidal load current.
The winding insulation must be designed for the aforementioned insulation levels. Not only
appropriate calculation methods are important to be able to assess the impact of the DC
stresses, but also a precise knowledge of the electrical characteristics of the materials used [2].
The design criterion is still the permissible field strength for a specific insulation, depending
on the materials used and the field distribution. As the same criteria apply to the 800 kV
transformer as to transformers with a lower rated voltage, this inevitably leads to significant
enlargement of the valve winding's insulation distances. Particularly in the winding end
insulation, this leads to a clearly higher number of angle rings and caps, with the associated
washers and seal rings (Fig. 3,4,5). Thus, tolerances of dimension and position of the
individual insulation parts have a clearly greater influence on the production process than in
the case of conventional transformers.

Fig. 3: Fig. 4: Fig. 5:

3) Winding end insulation of the valve winding
4) Winding block assembly; 5) 3d DC field simulation for a typical HVDC top winding geometry

3
2.4 Valve lead, valve bushing and associated barrier system

Valve leads are used to link the three parallel-connected valve windings with the valve
bushings. The valve leads consist of an insulated shielding tube around which several
pressboard barriers are arranged concentrically. Inside this shielding tube there are the
current-carrying conductor lines, which connect the individual winding ends to the valve
bushings. The aforementioned inner tube therefore serves only as an electrical shield that is at
high-voltage potential.
The barrier system consists of shaped pressboard parts that are fixed concentrically to one
another with the aid of spacers. A total of two systems is needed to connect the three upper
and the three lower winding ends to the two valve bushings. Both are almost identical and
differ only by virtue of the valve bushing's angle. This enables relatively uncomplicated
production, while at the same time reducing the number of shaped pressboard parts needed.

Technically, the barrier system together with the valve bushing is the most sophisticated
element of an HVDC transformer [3] [4]. This is due to the use of three materials, each with
different permittivity and conductivity values. The bushing and the associated barrier system
were therefore developed much sooner than the first transformer, in close cooperation
between the Siemens AG Nuremberg transformer factory and HSP of Cologne. An RIP
bushing is used that is provided on the air side with an SF6-filled combined insulator with
silicone shields. Extensive prototypes were manufactured and type tests were conducted (Fig.
6).
The test voltages for the valve bushings are a further 10% to 15% above the values of the
transformer specified in Fig. 1.

Fig. 6: Prototype test of the 800 kV bushing at the test bay of the Nuremberg transformer
factory (left), and type testing at HSP in Cologne (right)

4
The advantage of a dry type RIP bushing is that no oil-filled part protrudes into the valve hall
of the rectifier system. Therefore, the fire load is substantially lower, thus considerably
boosting overall system safety.
The SF6 pressure in the outer insulating body is monitored continuously during operation.

2.5 Tap changers

The tap changers of HVDC transformers are switched frequently. One hundred switching
operations per day or more can occur.
When operated on an HVDC system, the tap changers are subjected to higher stress because
the load current is nearly rectangular, and thus higher rates of rise occur than in the case of
sinusoidal currents.
In the past, this often led to a situation in which a number of single-phase tap changers were
used in HVDC transformers to distribute the switching capacity over several of them. Due to
the switching frequency, they were then often also equipped with oil filter systems to lengthen
maintenance intervals. This led not only to higher procurement and maintenance costs, but
also to an increased space requirement for tap changers and motor drives.
For the first time ever, vacuum tap changers from Maschinenfabrik Reinhausen are being
used for the 800 kV HVDC transformers. In contrast to the conventional tap changer, vacuum
interrupters are used here instead of the familiar erosion contacts. This allows voltage control
on the power system side with only one tap changer. The transformer's volume is therefore
also reduced. The maintenance intervals for this tap changer are clearly longer and this brings
considerable advantages for operators.

2.6 Tank and cooling system

Due to the outer connection of the three valve windings, the tank differs clearly from
conventional designs. The tank wall on the valve side has six large openings for the valve
leads. This must be taken into account when performing the structural analysis on the tank.
In addition, the two valve lead boxes with the valve bushings also introduce considerable
forces into the tank. The appropriate mechanical strength with the least possible use of
material was optimized in several steps by means of FEM calculations.

Fig. 7a: Fig. 7b:

“v. Mises stress” in the vessel under operating conditions (a) and during the period of time while the
vessel is under vacuum (b)

The transformer tank is a closed vessel containing the active part (core and windings)
submerged in a highly-refined mineral oil. The main components of this vessel are the tank
base, the cover and the boxes for the valve leads. Normal considerations related to the tank
and cover design include requirements for oil filling, draining, oil sampling, internal

5
inspection, handling and transportation. The transformer tank also serves as support structure
for accessories, cooling system and control equipment. The separate arrangement of the valve
lead boxes outside the tank of the transformer active part requires detailed FEM- calculations
(Fig. 7).

The outer dimensions of the tank were

affected by serious transport limitations
caused by the Chinese railway regulations.
Magnetic shunts and non-magnetic screens
were applied inside the tank to reduce heating
effects induced by magnetic stray-fluxes.
Particular assembly devices and 3D-animated
installation instructions were generated
because of the complexity and the dimensions
of the valve bushings and the valve lead
boxes (Fig. 8).
The conservator contains a flexible synthetic
rubber diaphragm, which allows for oil
Fig. 8: Assembly device for the valve-lead box expansion, but seals the oil from the
atmosphere.
The type of cooling for the transformer is ODAF. The related efficient heat transfer enables
relatively high current densities in the windings. This leads to optimized overall use of
material. In HVDC transformers this type of cooling is mainly used because, in most cases,
high power values have to be ensured with low transport dimensions.
Oil/air coolers are used to transfer heat to the environment. The transformer is equipped with
a total of four cooling circuits, one of which acts in a reserve or supplementary capacity for
overload operation. The arrangement of the coolers on the transformer tank is unusual,
essentially due to the limits of overall dimensions. In comparison with the conventional
arrangement in front of the transformer, however, it also offers thermal advantages because
the warm air from the transformer boxes at the place of installation is guided directly
upwards.

2.7 Tests
The tests on HVDC transformers are mainly defined in IEC 60378-2. Often, however,
customers specify additional tests or different acceptance criteria.
Besides the measurements usual for any transformer (winding resistance, losses, impedance
values, heat development etc.), it is the dielectric tests that pose the special challenge due to
the test voltages and times involved (Table 1). As already mentioned, the test levels of the
associated valve bushing are a further 10% to 15% higher (depending on the type of test
voltage).

Table 1: Comparison of test voltage levels of valve windings of 500kV and 800kV HVDC transformers
Voltage Testing 500 kV HVDC 800 kV HVDC Change in %
Transformer Transformer
AC long duration (1h) 600 kV 909 kV +52
DC long duration (2h) +800 kV +1254 kV +57
PR polarity reversal testing ±580 kV ±969 kV +67
(neg./pos./neg.)
(90min/90min/45min)
LI lightning impulse testing 1550 kV 1800 kV +16
SI switching impulse testing 1300 kV 1600 kV +23

6
In particular the SI switching impulse voltage and the AC voltage levels call for appropriate
shielding measures on both the valve bushings and the connections to the test voltage
generators, to avoid external flashovers and corona discharges. This is why the required
shielding electrodes for electric field control were developed separately and tested in advance.
In particular the applied AC voltage tests (separate source) of a level of 909 kV called for the
procurement of a new resonance testing system (Fig. 9). This system provides the test voltage
with a partial discharges level lower than 10pC.

Fig. 9: Prototype of the 800 kV HVDC transformer in the test bay of the Siemens AG Nuremberg
transformer factory, with 1200 kV resonance testing system

As the transformer ready for testing (including the valve bushing and shielding body) is over
26 m long, the transformer had to be placed diagonally in the test bay to ensure adequate
clearances from the hall's walls. The connection to the high-voltage generators is made by
flexible aluminum tubes to avoid partial discharges. In September 2008 the first 800kV
HVDC transformer in the world passed all tests successfully in the Siemens transformer
factory Nuremberg.

3 FURTHER REMARKS

The development of a transformer for 800 kV HVDC transmission is a milestone in

transformer technology.
Product development and production call for close cooperation between all those involved,
i.e. the system planners, the transformer manufacturer and the relevant material suppliers.
New design and production technologies were developed in many areas.

7
BIBLIOGRAPHY

[1] P. Heinzig, J. Hoppe:

Manufacturing reliable HVDC Transformers; TRAFOTECH 2006, Mumbai; 2006
[2] A. Küchler, F. Hüllmantel, J. Hoppe, D. Jahnel, C. Krause, U. Piovan, N. Koch:
Impact of dielectric material responses on the performance of HVDC power transformer
insulations; ISH03, Delft, 2003
[3] A. Küchler, M. Siller, H. Hoffman, C. Krause, N. Koch, J. Hoppe, P. Heinzig:
Transient stress management in HVDC barrier-oil insulation systems; ISH03, Delft,
2003
[4] M. Haeusler, H. Huang, K. Papp:
Design and Testing of 800kV HVDC Equipment, CIGRE 2008, Paris

8
 BIOGRAPHIES

Mario Schenk was born in Rochlitz, Germany, on September 27th, 1969.

He graduated from Dresden University of Technology in 1997 in High
Voltage and High Current Engineering. He holds a Dr.-Ing. from TU
Dresden (2002) and an Executive MBA from Kellogg-WHU (2006). He
started his professional career in a research project with ABB in Zurich
and continued in R&D with SGB in Regensburg, where he later became
Head of Engineering. He is heading the Engineering Department of
Siemens Power Transformers Nuremberg since 2007.

Peter Heinzig was born in Zwickau, Germany, on August 18th, 1962.

He graduated from the Technical University Ilmenau and received his
Dipl.-Ing. in High Voltage Engineering and Insulation in 1989.
He worked for Siemens Power Transformers from 1990 to 2008 and was
Principal Engineer in Nuremberg. He is active member in
CIGRE WG B4/A2-28 and member of IEEE Transformers Committee.

Uwe Rimmele was born in Berlin, Germany, on December 26th, 1961.

He graduated from University of Applied Sciences Berlin and received
his Dipl.-Ing. (FH) degree in Energy Systems. He has a wide range of
experience in the field of power transformers for more than 20 years. He
has been working for Siemens Power Transformers Nuremberg,
Germany, since 1996 where he became Head of the Design Department
in 2003.

Jens Hoppe was born in Dresden, Germany, on July 24th, 1962.

He graduated from Dresden University of Technology and received his
P.h.D. in 1992. He has been working for Siemens Power Transformers
since 1992 and is responsible for dielectric design and especially HVDC
Transformer development in the R&D department in Nuremberg.

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